Documente Academic
Documente Profesional
Documente Cultură
1.1
1.1.1
1.1.2
1.1.3
1.2
1.2.1
1.2.2
Methane ............................................................................................................ 13
1.2.3
Hydrogen .......................................................................................................... 14
1.2.4
Water ................................................................................................................ 15
1.3
1.3.1
1.3.2
1.3.3
1.4
1.4.1
1.4.1.1
1.4.1.2
1.4.2
1.5
Pathway............................................................................................................ 21
1.4.2.1
1.4.2.3
1.5.1
Land .................................................................................................................. 28
1.5.2
Market ............................................................................................................... 30
1.5.3
Roads ................................................................................................................ 30
1.5.4
1.5.5
1.5.6
Transportation ................................................................................................... 32
CHAPTER 2......................................................................................................................... 33
PROCESS MODELLING AND FLOWSHEETING .................................................... 33
2.1 Introduction ................................................................................................................... 33
2.2
2.2.1
2.3.1
Reactor .............................................................................................................. 39
2.3.2
Deethanizer .................................................................................................................... 40
Debutanizer ................................................................................................................... 42
Depropanizer ................................................................................................................. 42
Reboiler and Condenser ................................................................................................ 43
Recirculation Pumps ..................................................................................................... 43
2.3.3
Mixer ................................................................................................................ 44
2.3.4
Compressor ....................................................................................................... 44
2.3.5
2.3.6
Pump ................................................................................................................. 46
Introduction .............................................................................................................. 47
3.2
3.3
3.4
3.4.1
Reactor .............................................................................................................. 50
3.4.2
3.4.3
3.4.4
Pump ................................................................................................................. 56
3.4.5
3.4.6
Mixer ................................................................................................................ 58
3.5
3.5.2
3.6
Justification............................................................................................................. 66
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.2
4.2.1
4.3
4.3.1
4.3.2
4.4
5.1
Introduction ............................................................................................................ 81
5.1.5.2
5.1.5.3
6.1
Introduction ............................................................................................................ 93
6.2
6.3
6.4
Fixed Investment Cost (FIC) and Total Investment Cost (TIC) ........................... 96
6.5
6.6
6.7
6.8
7.1
7.2
7.3
7.3.1
7.3.2
7.3.3
7.5
7.6
8.2
8.2.1
9.1
9.2
CHAPTER 1
INTRODUCTION
1.1
Process Background
The main objective of preparing this design project is to propose the most suitable
plant design of producing 100,000 MMSCFD of liquefied petroleum gas (LPG). There
are several processes of producing LPG and it will be further discuss in this report.
LPG was first identified as a significant component of petroleum in 1910. The person
who discover the LPG was Dr. Walter O. Snelling, a chemist and explosive expert in U.S.
Bureau of Mines. He discovered that a large part of liquid gasoline was actually
composed of LPG, including propane, butane, and other hydrocarbons. This happens
when he realized that the liquid methanol was evaporated at a rapid rate. Snelling soon
realized that the LPG could be used for lighting, metal cutting, and cooking. So, created a
ways to liquefy the LPG during the refining of natural gasoline. He started a company
along with others cooperation called American Gasol Company, the first commercial
marketer of LPG. Snelling managed to produce relatively pure propane by 1911 and, in
1913, his LPG technology was awarded a U.S. patent.
Later that year, the patent was bought by Frank Philips, the founder of the Conoco
Philips oil company. Information concerning practical use of LPG dates to 1918, when
the fuel was utilized for brazing lamps and metal-cutting blowtorches. However,
commercial production did not begin until the 1920's. LPG sales in the US topped 223
thousand gallons in 1922, while within the next 3 years the figure grew to 400 thousand
gallons. In 1928, LPG was first used as motor fuel (in a truck) and the first LPG
refrigerator was made. In 1929, the level of sales of the fuel was as much as 10 million
gallons in the US. By 1912, propane gas was cooking food in the home. The first car
powered by propane ran in 1913. By 1915 people were using propane in torches to cut
through metal. LPG has been used as a transportation fuel, mainly in heavy trucks and
forklift vehicles, around the world for more than 60 years.
LPG processing involves separation and collection of the gas from its petroleum base.
LPG is isolated from the petrochemical mixtures in one of two ways -- by separation from
natural gas or by the refining of crude oil. Both processes begin by drilling oil wells. The
gas/oil mixture is piped out of the well and into a gas trap, which separates the stream into
crude oil and "wet" gas, which contains natural gasoline, LPG and natural gas. The
heavier crude oil sinks to the bottom of the trap and is then pumped into an oil storage
tank for refining. Crude oil undergoes a variety of refining processes, including catalytic
cracking, crude distillation, and others. One of the refined products is LPG. The "wet"
gas, off the top of the gas trap, is processed to separate the gasoline (petrol) from the
natural gas and LPG. The natural gas, which is mostly methane, is piped to towns and
cities for distribution by gas utility companies. The petrol is shipped to service stations.
The LPG also enters the distribution pipeline, where it eventually finds its way to end
users, including for home and commercial LPG users all around Australia and the world.
Liquefied Petroleum Gas (LPG) is a byproduct of natural gas extraction and crude oil
refining. It is considered a clean and environmentally-friendly source of energy. If made
available as a cooking energy fuel it could help to reduce the negative health impacts of
2.6 billion people who currently use biomass stoves that emit harmful smoke and
particles due to incomplete combustion. Varieties of LPG bought and sold include mixes
that are primarily propane (C3H8), primarily butane (C4H10) and, most commonly, mixes
including both propane and butane. In the northern hemisphere winter, the mixes contain
more propane, while in summer, they contain more butane. In the United States,
primarily two grades of LPG are sold: commercial propane and HD-5. These
specifications are published by the Gas Processors Association (GPA) and the American
Society of Testing and Materials (ASTM). Propane/butane blends are also listed in these
specifications.
Propylene, butylenes and various other hydrocarbons are usually also present in small
concentrations. HD-5 limits the amount of propylene that can be placed in LPG to 5%,
and is utilized as an autogas specification. A powerful odorant, ethanethiol, is added so
that leaks can be detected easily. The internationally recognized European Standard is
EN 589. In the United States, tetrahydrothiophene (thiophane) or amyl mercaptan are
also approved odorants, although neither is currently being utilized.
LPG example
Formula
EN 589: 2008+A1:2012
x%, C3H8
x%, C4H10
44-58
82 - 83/17 - 18/0
wt%
Applicable compression ratios
11 13
0.5 - 0.58
Boiling point, C
-42 - -0.5
210 810
20C, kPa
LHV heating value, MJ/kg
44 46
23 26
HHV, MJ/kg
48 -50
358 -372
kJ/kg
Self-ignition temperature, C
365 470
15.4
0.5
Hydrogen sulphide
Negative
50
Unpleasant and
distinctive at 20% LFL
*varying butane/propane ratio, e.g. 70% propane & 30% butane to 100% propane [IEA
1999]
LPG can be used in many applications in the industrial sector namely in space- and
process-heating, powering industrial ovens, production of food, kilns, furnaces, production of
packing material as well as in powering forklift trucks in warehouses.
Ceramic
LPG is one of the best choices of energy in this particular industry. Ceramics made of
clay require a high heating value in order to dry and become hard and solid. Easily
controllable, LPG provides clean combustion and is therefore advantageous in the
maintenance process. Burners and kilns have to be maintained less often causing less
downtime, with the consequence of saving costs and increasing productivity. As a choice
energy, LPG is widely used in pottery, roofing, ceramic tiles and sanitary ware.
Food Processing
LPG is widely used in many food processing systems because of its clean burning
properties. Bakeries and the manufacturers of biscuits, chips and chocolate are inclined
to choose LPG as their preferred energy option as their products will not be exposed to
the risk of contamination. In addition, this energy is also used in slaughterhouse for the
cleaning of facilities and sterilisation, pork butchery in the process of cooking, drying
and smoking as well as in the dairy industry for pasteurisation.
Textile
polymerisation.
Ironing
Total gaz LPG has multiple advantages in that it is clean and flexible, easy to
maintain and produces a high thermal yield.
Printing
Chemicals production
10
Although chemical engineering is the biggest user of steam boilers, LPG-powered heatexchangers are recommended in a number of different stages of the process. By using
LPG, the chemical processes are enhanced thanks to good temperature regulation
attributes, very high yields of energy and low maintenance procedures that are required
by this type of installation.
Forklifts
Good for meeting air quality regulations in the workplace and technical demands for a
modern handling (rapidity, power, flexibility, economy), LPG is nowadays the best
response for the fuelling of thermal-engine trucks. Lead-free and soot-free, LPG has a
very low rate of carbon monoxide emissions and is therefore the chosen energy when a
pollution-free environment is critical. Should you invest in new forklifts trucks, there
are many reasons why you should use LPG models.
1.2
Physical properties are alteration in temperature and pressure than can be measure by
measurement tools. Physical properties include formula weight, refractive index, specific
gravity, melting point, boiling point, solubility and others. Chemical properties describe the
procedure of a chemical reaction and substances that forming a solution. For example
enthalpy, entropy, heat capacity and others. It is essential to know the physical and chemical
properties of the chemical used in order we can alter and manage the chemical easily and
reduce the possibility of avoidable accident. In this following section, the physical and
chemical properties of various chemicals are listed in the table
11
CH3OCH3
46.07
Appearance
Colorless gas
Odor
Typical
Density, kg/cm3
2.1146
Melting point, K
132
Boiling point, K
249
Solubility
71 g/dm3 in water at 20 C
n/a
65.57
-184.1
fH298
Std enthalpy of combustion,
-1.4604
cH298
Auto-ignition temperature, C
350
Explosive limits, %
27
12
1.2.2 Methane
CH4
16.04
Appearance
colorless
Odor
odorless
Density, g/cm3
0.42264
Melting point, K
90.7
Boiling point, K
111.66
Solubility
14 nmol/Pa.kg
35.69
186.25
fH298
Std enthalpy of combustion,
-891.1 - -890.3
cH298
Auto-ignition temperature, C
537
Explosive limits, %
4.4 -17
13
1.2.3 Hydrogen
Table 1.4: Properties of Hydrogen
Molecular formula
H2
1.008
Appearance
Colorless gas
Odor
Typical
Density, g/L
0.08988
Melting point, K
13.99
Boiling point, K
20.271
Solubility
Henrys law constant, KH
n/a
14.31
fH298, kJ/mol
Std enthalpy of combustion,
-286
cH298, kJ/mol
Auto-ignition temperature, C
Explosive limits, %
14
1.2.4 Water
Table 1.5: Properties of water
Molecular formula
H2O
16.04
Appearance
colorless
Odor
odorless
Density, g/cm3
0.42264
Melting point, K
273.15
Boiling point, K
373.15
Solubility
yes
n/a
35.69
n/a
fH298
Std enthalpy of combustion,
n/a
cH298
Auto-ignition temperature, C
n/a
Explosive limits, %
n/a
15
1.3
Market Analysis
Liquefied petroleum gas or liquid petroleum gas (LPG), some country also referred it
as simply propane or butane , are flammable mixtures of hydrocarbon gases used as fuel in
heating appliances, cooking equipment, and vehicles. Varieties of LPG bought and sold
include mixes of propane and butane. At the northern hemisphere, in winter, the mixes
contain more propane, while in summer, they contain more butane. LPG is prepared by
refining petroleum or wet natural gas.
Dimethyl ether (DME), also known as methoxymethane, is the organic compound and
the simplest ether. It is colourless gas that is useful precursor to other compounds and an
aerosol propellant and is being studied as a future energy option. The largest use of DME is
as the feedstock for the production of the methylating agent. A mixture of DME and propane
is used in an over-the-counter device to treat warts, by freezing them. A potentially major use
of DME is as substitute for propane in LPG used as fuel in household and industry.
A spike in Asian LPG prices caused the US-Asia business window to re-open after
several months of closure, but market sentiment is that such high US-Asia price differentials
are not expected to last for long. In that case, most of the US exports in 2015 would be
contractually-committed, since exporters are understood to have hedged through 2015; these
should still be economically viable.
The US is, however, not the only region that increases exports in 2015. The Arabian
Gulf is forecast to grow by around 1 mm t where, in particular, it expected more LPG out of
Abu Dhabi, Kuwait and Iran. There may also be higher exports out of West Africa if Angola
finally gets its new LNG plant operating properly.
On the other hand, European exports are expected to decrease overall, with lower
North Sea producer exports offsetting higher ex-Russia volumes. The majority of the
increased global exports will go to Asia, which is forecast to see its imports rise from just
over 43 mmt to 45.5 mmt. Imports into the Med and Latin America are also expected to rise.
16
Within Asia, it is China and India looking most likely to show high growth, in China
this is highly dependent on the start-up and operation of still more new propane
dehydrogenation (PDH) facilities; in India it is the development of the rural LPG market that
leads the way, although the size of this Indian growth increase will depend on the
governments approach to subsidies.
Thai imports may also expand, spurred on by high auto-gas demand growth, but here
the withdrawal of government subsidies, if fully implemented it could have a dampening
effect on retail market demand. Same thing could also apply in Indonesia.
In 2014 and 2015, past this full year, show the largest exporting region remained the
Arabian Gulf (AG), accounting for an estimated 45% of all exports with the majority of LPG
from the AG going to Asia (96%). Of the total 34.48 mmt of AG exports, Qatar and Abu
Dhabi accounted for 10.4 and 9.6 mmt respectively. Shale developments in the US during
2014 significantly increased exports from there, with total US exports for the year estimated
to be around 14 mmt, 5.2 mmt higher than in 2013. Trade between North America and Latin
America increased, as well as from North America to Northern Europe, mainly at the expense
of West Africa. As a result, West Africa moved more shipments east through 2014.
Diagram below show the global LPG consumption from 2000-2010. From the data we
find that Asia Pacific consumption has increase rapidly, from 55,000-89,000 MT. The
consumption of LPG are expected to keep increasing in the future especially in the Asia
Pacific region.
17
The Asia-Pacific region is the largest market for DME in the world. Jiutai Energy
Group (China), China Energy Limited (Singapore) are the leading players in the Asia-Pacific
market. DME is majorly used for LPG blending purpose followed by aerosol propellant. In
Asia-Pacific region the capacity has gradually increased and it will grow continuously with
new plant establishment for the domestic fuel supply. Asia-Pacific is a developing region.
Also, being the most populated region global, the demand for fuel substitutes is the highest in
this region. These factors drive the demand for fuel substitutes such as DME. Major countries
which contributed the maximum shares in this market are China, Japan, South Korea, and
Indonesia.
Most of the DME produced these days is an output of a two-step process in which the
first one is methanol generation by using coal or natural gas as a feedstock and the second is
methanol dehydration to produce DME. Coal is employed as a feedstock in Asian countries
while countries such as Papua New Guinea and Saudi Arabia focus on natural gas reforming
to produce methanol and then convert it to DME. Major DME manufacturers include Akzo
Nobel N.V. (The Netherlands), Royal Dutch Shell Plc. (The Netherlands), The Chemours
18
1.3.3
Diagram below show the LPG consumption for Malaysia from 1986 to 2010, the data
being provided from The U.S. Energy Information Administration. The average value for
Malaysia during that period was 34.94 thousand barrels per day with a minimum of 3.87
thousand barrels per day in 1986 and a maximum of 85.96 thousand barrels per day in 2010.
1.4
Process Selection
Producing Liquefied Petroleum Gas (LPG) by using Dimethyl Ether (DME) can be
achieved by two methods which are first by buying the DME from a DME producing plant or
second by producing the DME ourselves.For the first method, DME will be supplied by a
local or international company to meet our need. For the second method, two step process is
chosen because currently there is more widespread application of the two-step process since
it is relatively simple and start-up costs are relatively low. Two step process means there will
be a dual catalyst system that permits both methanol synthesis and dehydration in the same
process unit, with no methanol isolation and purification.
20
1.4.1
Pathway
There are two pathways that will be discussed in this section. The best pathway will
be chosen by looking at its efficiency economically and so on.
In this process, the raw material will be DME and hydrogen. Both of the raw material
will be supplied by the supplier company. Firstly, the DME is dehydrated to generate a
carbene (H2C:) by a concerted catalysis of an acidic site and a basic site, which are at spatial
field inside a pore in a zeolite catalyst. Then, the carbene is polymerized to form an olefin
containing propylene or a butene as a main component. After that, olefin-hydrogenation
catalyst will be used to turn olefin into paraffin. Then, water, a low-boiling component such
as hydrogen, and a high-boiling component is separated from the lower-paraffin-containing
gas produced, as necessary, to obtain the LPG. If necessary, the gas may be pressurized
and/or cooled so as to obtain the LPG. The chemical reaction will be as follows :
+ 2
1.4.1.2
direct or indirect process. Basically, the process to produce DME from natural gas feedstock
is made up of the reaction to reform raw material methane into syngas by using steam or
oxygen as oxidant. Next, from syngas will produce methanol and then methanol will be
dehydrated to DME. Both routes have same principle of DME production, but the different
between them is the direct route makes methanol synthesis reaction and DME synthesis
21
reaction occur in one reactor, while the indirect route makes these reactions in separate
reactor. Both routes have their own advantages that would be discussed in next section.
However, in this process we prefer direct route to produce DME.
Figure 3: Reactors and process layout for syngas production from natural gas and shale gas.
Figure 4: Schematic diagram of a tubular reactor for bench scale conversion of syngas to
DME.
22
There are several ways can be taken in order to obtain an end product of LPG. But,
the production of LPG also is the same like the others product in the industry which must
consist of the reference or theoretical step in their production before the management along
with the engineers in each company change their own raw material based on the reference
step. In the calculation, we will explain thoroughly the reasons for each company to change
their raw products instead of following the theoretical steps.
Note: Some assumption had been made in this calculation due to the pricing range. As the
profits that need to be count is estimated one, some value than within the range is being
taken. The maximum values has been taken for the product price while the minimum prices
being chosen for the reactants in order to maximize the profits gain. All information
regarding the prices had been retrieve from ICIS website (ICIS,2015).
Molecular
weight $/kg
RM/kg
(kg/kmol)
DME
46.07
0.438
1.785
H2O
18
0.02
0.07
LPG
44.01
0.8182
3.33
23
DME
H2O
LPG
Kmol
MW
46.07
18
44.01
Mass
46.07
18
44.01
kg/kg LPG
1.047
0.409
RM/kg LPG
1.869
0.029
3.33
2. Syngas to methanol
Water-gas shift reaction
CO + H2O CO2 + H2
Combination 2 and 3
CO + 2H2 CH3OH
Combination 1 and 4
CH4 + H2O CH3OH + H2
Overall equation:
24
Compound
CH4
CH3OH
CH3OCH3
H2
CH4
1
16.04
16.04
0.348
0.1305
CH3OH
1
32.04
32.04
0.695
0.7214
CH3OCH3
1
46.07
46.07
1
1.78
H2
1
1
1
0.0217
0.272
General description on all the alternative pathways of LPG production from DME
using hydrogen have been discussed, hence in this section, all those pathways will be
compared in terms of economic potential, manufacturing process in terms of the operating
conditions (Briggs et.al, 1985).
NO.
Process
1) Zeolite
2) Olefin-
(by supplier)
Parameter
Temp: 450
Catalyst
dehydro
Advantages/Disadvantages
is
from
25
Pressure:
genation
0.15MPa
catalyst
supplier
Lower the
plant
cost as number of
process
unit
decrease
Simpler
chemical
process
reaction
involved
1)Copper
Relatively simple
natural
based
gas
and
catalyst
production
All the 2 production pathways have been thoroughly discussed and compared in terms of
their advantages, disadvantages. The most important considerations are being the feasibility
of the process commercially in economical and safety aspects. Conclusion, we decide to use
production of LPG from direct DME (by supplier) for our plant project.
1.5
Site Location
In order to produce LPG from DME, detail study regarding on site location need to be
carried out to make sure this project successful and effective. For the construction of the LPG
plant we have find out the industrial area that are suitable for the construction of the plant.
The location that is favourable is Teluk Kalong , Kertih or pasir gudang, Johor. The area is
ready-built factories, investors have the option of moving directly into ready-built factories
with preinstalled basic facilities like broadband, power and water, which reduces the time
needed to get a project off the ground.
To determine suitable site location, site study need to do and it includes a few element
such as land price, raw material availability, transportation, market, etc. Table 1 shows
information about site study.
26
Gas
Malaysia/
Terengganu
Gas
Electricity supply
(TNB)
173
RM 14 - 20
RM 45 - 60
40 km from Kemaman
Land Transportation
(LPT)
Port
Kemaman Port
Water Supply
Electricity Tariffs
Period Peak
42.70 Cent
42.70 Cent
Off-Peak
19.10 Cent
19.10 Cent
2.96 Cent
2.96 Cent
Worker Supply
Universiti
Malaysia (UTM)
College,
Terengganu
27
For long term period, the plant site can consequence capital cost, operational cost and
market price. Factors that need to put into consideration when choosing the proper plant
location included raw material availability and cheap, source of power and water, reasonable
land price, skilled man power, and last but not least good transportation network (via land,
sea and air)
Based on the detail information and consideration on table 1, our group had selected
the strategic plant location at Pasir Gudang, Johor. Justification and comparison for the
selection of pasir gudang johor compare to teluk kalong as below;
1.5.1 Land
Land play important role for the selection of site, because it can affect the capital
investment. The land with most economical and reasonable price would be an advantage in
capital cost. Based on table 1, land at pasir gudang had the lowest price per ft 2 compare to
teluk kalong. When the price of land is cheapest, the fund allocation to buy the land can be
minimized. The land characteristics (geological factors) at the proposed plant site should be
examined carefully. Sufficient suitable land must be available for the proposed plant for
future expansion. Besides that, there is still huge land available at Pasir Gudang compare to
Teluk Kalong. This advantage can be used to expand our plant in the future. A suitable land
should be ideally flat, well drained and have suitable load-bearing characteristics such as for
piling or other special foundation.
28
29
1.5.2 Market
The market that required LPG in bulk quantities should located close to the plant
where the production and transportation require a lot of cost. This consideration will be less
important for low volume production. Based on our local demand, there is huge market
demand for LPG as Johor is a developed state under ISKANDAR MALAYSIA and Pasir
Gudang also is an industrial area.
LPG is a product that be used in domestic and industrial sector that provide large
heating value. LPG is widely used in households for heating appliances such as stoves, ovens,
water heaters and dryers. It is an ideal fuel for cooking as it provides instant and consistent
heat which can be controlled easily. While for industries, LPG use for gas engines in forklifts,
industrial boilers, and etc because its reliable and steady.
1.5.3 Roads
Lebuhraya Utara Selatan (plus) only take 2 hours to travelled from Pasir Gudang to
nearest port which is pasir gudang port in which located 184km. Pasir Gudang also located to
almost the same distance to the port klanf which took 2 hours and half if travelling through
the highway. This highway makes it convenient for promoting economic activities in major
districts in johor. By have this accommendation, our company can reduce the time to for the
product and raw material transportation.
The source of raw material is one of the most important factors influencing the
selection of the plant site. The closer the site to the raw materials suppliers, the cost of
transportation will be cheaper. In earlier stages, we assume that the raw material, DME to be
imported from Indonesia. On the other hand, for future expansion the plant may produce their
own DME from natural gas. In advantage, Pasir Gudang had been supply with natural gas
30
from Petronas Gas or Gas Malaysia through gas transmission line as shown in figure 1. The
time to receive the raw material can be reduced as the pipeline provide continuos supply of
natural gas.
Water and electric power supply utilities are very important to make sure the
operation of plant effectively without any disruption, hence production of LPG going well.
Large quantities of water for cooling and general processes use and the plant must be located
near a source of water of suitable quality. The water may be drawn from a river, from wells,
or purchased from a local authority. Stable electrical power supply will be needed inorder for
the plant to run smoothly. The plant that requires large quantities of power to operate need to
be located close to a cheap source of power. With the supply of water from Syarikat Air
Johor (SAJ) and electricity from Tenaga Nasional Berhad (TNB), our plant can be smoothly
run for the whole schedule for the year.
31
1.5.6 Transportation
Transportation is on of the important factor for the site selection in order to buy the
raw material and to deliver product. If practicable, a site should be selected that is close to at
least two major forms of trans port such as road, rail or a sea port. Air transport is convenient
and efficient for the movement personnel and essential equipment and supplies. While, road
and sea transport is being increasingly used, and is suitable for long- distance transport of
bulk chemicals. The facilities at Johor such as Senai International Airport and Pasir Gudang
Port make it conductive for our plant and investment since the increase petrol fuel and toll
will affect the profit for the transportation.
32
CHAPTER 2
2.1 Introduction
In this chapter, we will mainly discussed about the process which includes the
chemical reaction, process unit and process condition. The modelling and flowsheeting is
constructed with a proper sequence to convert the raw material to desired product, liquefied
petroleum gas (LPG). The raw material for the process would be Dimethyl Ether (DME) and
hydrogen.
The plant is to produce a total amount of 100,000 metric ton LPG per annum. The
operating day for this plant is 335 days per year and 24 hours a day. The LPG to be produced
should have more than 60% of propane purity, less than 40% butane purity and less than 2%
of other hydrocarbon purity in order to be sale in the market.
In this LPG plant design, there are several main synthesis and process would be
involve which are :
Mixing section
Hydrocarbon synthesis
33
2.2
There are several LPG synthesis methods but those synthesis methods have different
raw material and yield different composition as well as the product composition. These are
the synthesis methods that have been discussed in Chapter 1:
As been discussed in Chapter 1, the raw material of pathway 2 is natural gas which is
to produce DME which then are used to poduce LPG while in pathway 2 the raw material is
DME which are supplied by the supplier. Eventhough, the gross profit for pathway 2 is
mostly desirable compared to Pathway 1, we will be choosing pathway 1 because of its
inherent safer (simplification of process and minimization of the number of process unit) and
cheaper than pathway 2.
30002 + 100
2.54 + 2.0 + 52.53 8 + 32.84 10 + 8.35 12 + 0.96 14 + 0.3
34
(1)
Conversion of reactant DME for producing LPG for both process are 100%.
According to the third synthesis step, there are some product stream components that
needed to be separate by certain separation equipments.
The separation above is based on the heuristic for determining favorable sequences:
35
From the process flow diagram above, we can see that, to eliminate the difference
between temperature, pressure and phase, we are using temperature changer which is heat
exchanger and for pressure, we are using compressor and pump to change the pressure.
36
2.3
Process Description
In this De-Ethanizer, 100% methane and ethane in mixed feed can be separated and
leaves the top of the column at 31 bar and 4.39 oC. The heavier hydrocarbons other than
ethane leave the column as bottom product in liquid phase at 31.35 bar and 103.67 oC. Next it
is sent to debutanizer column.
Since the bottom product of De-Ethanizer composed of propane (55.12 % of mass
fraction) and butane (34 % of mass fraction), De-Butanizer is used instead of De-Propanizer.
So that smaller columns will be used for next extraction. This is not only for economic
reason, but also for efficiency of the separation as it is easier to extract the product this way
and less duty will be required for reboiler E-RB2.
Before entering De-Butanizer column, the De-Ethanizer bottom product is expanded
from 31.35 bar to 7 bar using several pressure relieve valve (RV-100,101,102) and fed into
De-Butanizer as liquid feed. This feed is fractionated into mixed propane and butane as
overhead product and heavier hydrocarbons (C5 +) as bottom product. Then the overhead
product is totally condensed in the condenser by heat exchange with cooling water, and
condensate is collected in reflux drum. The cooling water is sea water with temperature 10 oC.
The reflux drum should be used in order to prevent cavitation on the pump due to vapor
phase. The De-Butanizer reflux and product pump P-101 serve the dual purpose of supplying
reflux to the column.
About 100% propane and 99% butane can be recovered from the feed at the overhead
column product. This stream leaves the column at 7 bar and 36.36 oC and is sent to DePropanizer column to separate propane and butane. Meanwhile, the bottom product
composed of pentane and heavier hydrocarbons will be stored as natural gasoline. Since the
bottom product has high temperature (111.12oC), it will be cooled by heat exchanger E-CL100 before being sent to the storage tank.
Propane and butane stream is expanded from 7 bar to 15 bar and enters the DePropanizer as mixed-phase feed. The De-Propanizer separates propane as overhead product
and butane as bottom product. Sea water is used for cooling. Condensate is collected in DePropanizer column reflux drum D-102. De-Propanizer reboiler heat is supplied by reboiler ERB3. Reboiler circulation is aided by reboiler circulation pump.
It is about 99.9% of propane can be recovered as top product and 99.9% of butane is
recovered as bottom product. The butane product is field grade butane which is composed of
38
41% i-butane and 56% n-butane. After De-Propanizer, the product (LPG fractions) will be
mixed according to LPG standards so that it can be commercialize.
2.3.1 Reactor
A DME Conversion Experimental Process Unit has been designed and set up which
includes a fixed bed reactor. This type of reactor move uniformly and the production of byproduct is reduced.
39
Figure 2.3: Schematic diagram of Conventional Column (D-01), (D-02) & (D-03)
Deethanizer
After selected the feed conditioning process, next step is defining the process in the
deethanizer column as well as converging the column. In order to minimize the cost, it is
avoided to use refrigerant. Therefore, there will be no condenser that is used at the overhead
column stream as shown in Figure 3. Methane and ethane as top products will be separated in
gas phase. By deleting the condenser there will be no reflux stream at the top of column.
40
First step to do after defined stream connection is selecting the operating pressure at the top
and the bottom of the column. As initial guess, 26.9 bar pressure was used based on
reference. Since the feed pressure is 310 bar, expansion valve is added in order to meet the
operating pressure of the column. Afterwards select the parameter which will be used as
column specification to converge the deethanizer column. In this case, since condenser is not
used, there will be only one column specification needs to be defined to converge the column.
Selecting operating pressure at the top and the bottom of the column is very important to
separate the methane and ethane. The lower the pressure the more the vapour phase. The
operating pressure has to be selected so that most methane and ethane flow to overhead
column and keep propane and heavier hydrocarbons as the bottom product. The best result is
to select operating pressure 18 bar at the top stage and 26 bar at the bottom stage. Next step is
selecting the column specification. As mentioned previously, there is only one column
specification in modelling the deethanizer column. In this case, the bottom product flow rate
is selected since it is the recommended and default specification for the column. Other
specification can also be selected, for example component fraction at the top or bottom stage,
but it would be very difficult to converge the column. It depends on the composition of the
feed. In this case, the composition of methane and ethane in the feed is quite less, so that it is
very difficult to remain all the propane and heavier hydrocarbons in the bottom stage.
Practically, some trials have to be done to find the best result. As well as selecting
operating pressure and column specification, defining the number of stages is also quite
important. The more the number of stages means the better the separation process. In the
other hand, more number of stages means higher column is required and the cost will be more
expensive. Therefore, the number of stages has to be selected the optimum one considering
both separation efficiency and cost. As initial guess, the number of stages is defined based on
reference.
In order to find the optimum number of stages, the temperature profile of each tray
would help. As well as the column converged by using initial guess of number of stages, it
can be reduced to the optimum one by considering the temperature profile of each tray. At the
point where the column is no longer converged, the previous number is selected as the
optimum one. In this case, the optimum number of stages for deethanizer is 18 stages. After
converged the column and find the optimum one based on the separation efficiency and
economic consideration, the simulation is continued to modelling the debutanizer column.
41
Debutanizer
As mentioned previously in process description, for economic reason, debutanizer
will be used after deethanizer instead of depropanizer, so that the next separation will use
smaller column. Debutanizer is used to separate butane and lighter hydrocarbons at the top
and heavier hydrocarbons at the bottom. Basically, the steps in modelling the debutanizer
column are almost the same like modelling deetanizer. The differences are in selecting the
column specifications. Since both condenser and reboiler are used, there are 2 column
specifications to be defined in order to converge the column. In this case, components
recovery of the top product is selected as column specification. As it is expected to separate
propane and butane at the top and heavier hydrocarbons at the bottom, so that components
recovery of the propane and butane as the top product are selected.
Even though most propane and butane can be recovered as the top product, there is
one specification should be considered, that is reboiler duty. It is possible to have 99.99% of
propane and butane at the top, but more reboiler duty will be required. Thus, the fraction of
components recovery should be selected by considering minimum reboiler duty in order to
minimize the cost for the steam.
As well as modelling deethanizer, selecting operating pressure and number of stages
are also done in modelling debutanizer. Initial guess value for both specification are also
based on reference then have some trial to find the optimum value.
Depropanizer
42
operating pressure and number of stages are also done using initial guess value from
reference. Some trials still have to be done to find the optimum value.
Reboiler and condenser are parts of the columns. Reboiler is used to supply heat into the
column, so that the lighter hydrocarbons will be vaporized and go up to the top stage. Steam
is used to heat up a part of bottom product and recycle it into the column. Meanwhile,
condenser is used to condense the overhead vapor so the liquid product will be produced
which partially recycled into the column as reflux.
In simulation, as part of a distillation column, both reboiler and condenser are defined based
on requirement in order to meet product specifications.
Recirculation Pumps
Recirculation pump is used to recycle the reflux and heat supply into the column. It is not
shown in the simulation but still need to be calculated for the cost estimation.
43
2.3.3 Mixer
The dimethyl Ether and hydrogen are mixed well in the M-01 before they entering
reactor to ensure that all the reactor is perfectly mix each other. The mixer helps to enhance
the reaction in the reactor. While M-02, it function to mixed the final product out from the
conventional column, which is propane and butane. From the mixing process, it produced
well-mixed quality of LPG.
2.3.4 Compressor
44
Heat exchanger is used to transfer heat into or from the stream to the process fluid. In
most chemical reaction process heat transfer is required to heat up or cool down the stream of
fluid based on the process unit conditions. In this plant we used heat exchanger shell and tube
type which is cooler.
Cooler (HX-01): this cooler helps to decrease the temperature of stream from R-01 before
feed to D-01. The temperature was decreased from 329 degree C to 247 degree C.
Cooler (HX-02): This cooler help to reduce the temperature of stream from D-02 to be stored
in T-02.
Cooler (HX-03): This cooler helps to reduce temperature of stream from D-02 to feed to P03. The temperature reduce from 252 degree C to 77 degree C
Cooler (HX-04): This cooler helps to decrease the stream from D-03 to P-05. The
temperature reduced from 75 degree C to 23 degree C.
45
2.3.6 Pump
This is isothermal pump increasing the pressure of stream by moving the fluids. Pump
is identical to compressor but differ only in the phase involves. Pump is dealing only with
liquid phase while compressor is only for gas phase.
P-01: Helps to pump the fluid in liquid phase from D-01 to E-01.
P-02: Helps to pump the fluid in liquid phase from D-02 to E-02
The pressure relief valve (PRV) is a type of valve used to control or limit the pressure
in a system or vessel which can build up for a process upset, instrument or equipment failure,
or fire. The pressure is relieved by allowing the pressurised fluid to flow from an auxiliary
passage out of the system. The relief valve is designed or set to open at a predetermined set
pressure to protect pressure vessels and other equipment from being subjected to pressures
that exceed their design limits.
46
CHAPTER 3
3.1
Introduction
Material and energy balance seems to be an important factor in dealing with
the process synthesis and flow sheeting. It should be done first before the simulation
being carried out because the result of simulation is only used as a checking material
to the manual material and energy balance.
3.2
3.3
The procedure for doing the manual energy balance can get from Elementary
Principles Of Chemical Processes, page 312-315. The calculation is based the first
law of thermodynamics where kinetic energy differences, potential energy differences
and work done on the system by its surroundings are zero. So, the law become
Q = H = noo - nii
with reference conditions: the elements that constitute the reactants and products at
25C and the non-reactive molecular species at any convenient temperature. Each
enthalpy calculation is difference depends on the phase for that stream. If the phase is
in vapour form, specific enthalpy is calculated by If the stream is in the liquid-vapour
mixture form, the specific enthalpy can be calculated by using the following equation:
( , ) = + = , (1 ) + 2 ()
1
If the phase is in liquid form, the specific enthalpy can be calculated by using:
( , ) = + = ( , (1 ) + ()
())
Where:
49
( )
( )
( ) 0.38
(
)
( )
If the stream in liquid-vapour mixture forms, the specific enthalpy can be calculated
by using the following equation:
(, ) = (, ) + (1 ) (, )
Here, some assumptions have been made also. They are:
1. The process system is an open system.
2. Adiabatic process where no heat loss to the environment.
3. All the liquid and gas heat capacities are constant at certain temperature and
the value of heat capacities from simulator can be taken directly by setting the
simulator.
4. All the enthalpies calculated are taken at 25C at 1 atm as reference whereas
for non-reactive molecular species, the reference state is taken at any
convenient condition.
3.4
50
S-DME-F S-H2-F
S-1-V
S-1-L
14.0915 4.6065778 11.782724 12.782724
33.25467
-
66.74533
0.0252
0.0201
0.5287
0.1903
0.1400
0.0835
0.0091
0.0030
486.49
21
1807931.02
0.0154
0.0152
0.4822
0.2080
0.1553
0.1082
0.0139
0.0017
51
52
53
Feed
Distillate
Bottom
Flowrate (kmol/hr)
13.8099
0.6984
13.1115
C1
0.3421
0.3421
0.0000
C2 (L)
0.2869
0.2840
0.0029
C3 (H)
7.2987
0.0723
7.2264
I-C4
1.9376
0.0000
1.9376
N-C4
2.6320
0.0000
2.6320
C5
1.1809
0.0000
1.1809
C6
0.1317
0.0000
0.1317
CO
0.1317
0.0000
0.0000
Temperature c
84.0000
4.7800
104.3900
Pressure (bar)
31.0000
31.0000
31.3500
Mole fraction
4713.9385
1210963.5547 2033327.9783
Feed
Distillate
Bottom
Flowrate (kmol/hr)
13.1115
11.7827
1.3288
C1
0.0000
0.0000
0.0000
C2 (L)
0.0029
0.0029
0.0000
C3 (H)
7.2264
7.2264
0.0000
Mole fraction
54
I-C4
1.9376
1.9363
0.0013
N-C4
2.6320
2.6054
0.0266
C5
1.1809
0.0117
1.1692
C6
0.1317
0.0000
0.1317
CO
0.0000
0.0000
0.0000
Temperature c
58.7400
36.3600
111.1200
Pressure (atm)
7.0000
7.0000
8.0000
2033327.9783 -907899.4816
695109.7535
Feed
Distillate
Bottom
Flowrate (kmol/hr)
11.7827
7.1761
4.6066
C1
0.0000
0.0000
0.0000
C2 (L)
0.0029
0.0029
0.0000
C3 (H)
7.2264
7.1534
0.0730
I-C4
1.9363
0.0192
1.9171
N-C4
2.6054
0.0007
2.6048
C5
0.0117
0.0000
0.0117
C6
0.0000
0.0000
0.0000
CO
0.0000
0.0000
0.0000
Temperature c
36.3600
28.6500
77.8900
Pressure (atm)
15.0000
11.0000
12.0000
1666.4227
-538237.6692
585009.9769
Mole fraction
55
3.4.4 Pump
P-101
S-2-L
S-2-PMP Stream Tag
Flowrate
13.809944 13.809944
(kmol/hr)
Mole Fraction
0.0248
0.0248
C1
0.0208
0.0208
C2
0.5285
0.5285
C3
0.1403
0.1403
i-C4
0.1906
0.1906
n-C4
0.0855
0.0855
C5
0.0095
0.0095
C6
0.0000
0.0000
CO
Temperature
-100
(C)
1
31.35
Pressure (bar)
Heat Duty (
4713.938533
kJ/hr)
S-2-L
S-2-PMP
11.7827
11.7827
0.0000
0.0002
0.6133
0.1643
0.2211
0.0010
0.0000
0.0000
0.0000
0.0002
0.6133
0.1643
0.2211
0.0010
0.0000
0.0000
36.3600
37.8500
7.0000
15.0000
1666.4227
56
The description for mass balance calculation of heater is the same as cooler
with the exception of a positive heat duty.
S-1-MIX
13.86
S-2-CL
13.86
0.0250
0.0250
0.0207
0.0207
0.5266
0.5266
0.1398
0.1398
0.1899
0.1899
0.0852
0.0852
0.0095
0.0095
0.0033
0.0033
486.49
-100
21
1
1245350.746
57
3.4.6 Mixer
To calculate mass balance for mixer are relatively straight forward since the reaction
takes place inside the reactor.
S-1-V
S-1-L
S-1-MIX
0.0252
0.0201
0.5287
0.1903
0.1400
0.0835
0.0091
0.0030
0.0154
0.0250
0.0152
0.0207
0.4822
0.5266
0.2080
0.1398
0.1553
0.1899
0.1082
0.0852
0.0139
0.0095
0.0017
0.0033
486.4921665
21
-771733.9
0
-771733.871
58
0.3563
0.3663
0.2745
0.0000
0.0000
0.0000
0.0000
0.0029
4.78
31
-20.61513 -77982.49
0.4899
0.4066
0.1035
0.0000
0.0000
0.0000
0.0000
0.0000
-78003.1025
59
S-0V2-V
S-0V2-L
S-0V2-MIX
1.809E07
11.7827
11.7827
0.0000
0.0001
0.8098
0.0974
0.0927
0.0000
0.0000
0.0000
0.0000
0.0002
0.6133
0.1643
0.2211
0.0010
0.0000
0.0000
36.36
7
0.0250
0.0207
0.5266
0.1398
0.1899
0.0852
0.0095
0.0033
-0.01988
-1553201
1553201.09
60
178.18439
0.0000
0.0000
0.9961
0.0008
0.0030
0.0000
0.0000
0.0000
28.65
11
-859967
0.0000
0.0004
0.9968
0.0027
0.0001
0.0000
0.0000
0.0000
-859788.784
61
S-C3-CV S-C4-CV
S-LPG
7.1761465 4.6065778 11.78272424
0.0000
0.0000
0.9961
0.0008
0.0030
0.0000
0.0000
0.0000
28.65
11
1805500.4
0.0000
0.0000
0.0000
0.0002
0.0001
0.6133
0.5782
0.2211
0.4217
0.1643
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
77.89
77.89
12
0
1805500.445
62
T2-C4-V
T2-C4-L
S-C4
0.0252
0.0201
0.5287
0.1903
0.1400
0.0835
0.0091
0.0030
0.0154
0.0250
0.0152
0.0207
0.4822
0.5266
0.2080
0.1398
0.1553
0.1899
0.1082
0.0852
0.0139
0.0095
0.0017
0.0033
486.4921665
21
1805500.4
0
1805500.445
63
T1-C3-V
T1-C3-L
S-C3
0.0252
0.0201
0.5287
0.1903
0.1400
0.0835
0.0091
0.0030
0.0154
0.0250
0.0152
0.0207
0.4822
0.5266
0.2080
0.1398
0.1553
0.1899
0.1082
0.0852
0.0139
0.0095
0.0017
0.0033
486.4921665
21
1805500.4
0
1805500.445
64
3.5
Process simulation has been done on this LPG Plant assuming steady state
condition by using Aspen HYSYS Simulation Software. This software is a
comprehensive process modelling tool used by the worlds leading oil and gas
producers, refineries, and engineering companies for process simulation and process
optimization in design and operations of a plant. In this section we will compare the
material and energy balances between manual calculation and by using simulation.
The comparison is evaluated by using the following formula :
=
| |
100%
Table 17: Material Balances Comparison between Manual Calculation and Aspen Simulation.
Stream
Total Manual
Total Aspen
Error (%)
S-DME-F
S-H2-F
S-1-MIX
S-2-CL
S-2-V
S-2-L
14.0915
28.2830
13.8600
13.8600
0.0501
13.8099
14.1000
26.8730
13.9576
13.9576
0.1228
13.8348
0%
-5%
1%
1%
59%
0%
65
S-2-MP
S-0V1-MIX
S-B-1
S-B1-CRTV
S-B-2
S-0V2-MIX
S-0V2-VLV
S-0V2-PMP
S-0V3-MIX
S-B-3
S-C3-CV
S-C4-CV
S-LPG
13.8099
0.6984
13.1115
13.1115
1.3288
11.7827
11.7827
11.7827
7.1761
4.6066
7.1761
4.6066
11.7827
13.8348
0.7622
13.0727
13.0727
1.2933
11.7794
11.7794
11.7794
7.1960
4.5834
-
0%
8%
0%
0%
-3%
0%
0%
0%
0%
-1%
Table 18: Energy Balances Comparison between Manual Calculation and Aspen Simulation
Major Equipment
Reactor (CRV100)
Heat Exchanger
Condenser
(E-CND1)
(E-CND2)
(E-CND3)
Rebolier
(E-RB1)
(E-RB2)
(E-RB3)
Pump
P-100
P-101
3.6
Error
(%)
1805500.445
2.10E+06
1.81E+06
1293036.866
-40%
-1210963.555
-907899.4816
-538237.6692
-1557104183
-834392.9577
-550761.9683
100%
-9%
2%
2033327.978
695109.7535
585009.9769
1557434006
697640.908
593308.0119
100%
0%
1%
4713.938533
1666.422691
4195.548755
1209.370593
-12%
-38%
14%
Justification
66
There are several justifications about the percentage error occurring between
manual calculation and simulation such as the error between manual and HYSYS due
to the reference of each other are different. For manual calculation, the reference
based on 25 C, 1 atm. Besides that, the thermodynamic formula for such as specific
heat for manual and HYSYS are different. Furthermore, for manual calculation, the
temperature and pressure was set to be same for input and output. Meanwhile, in
HYSYS, the temperature and pressure was set in inlet stream only.
67
CHAPTER 4
4.1
This will then be followed by the design of the heat exchanger network using
the Pinch Technology Method. The Pinch Technology include deciding the position
of heat exchanger in a network together with the assumption on overall heat transfer
coefficient and it was developed as a systematic tool to design heat recovery network
for maximum energy recovery. The procedures are based upon fundamental
thermodynamics and a set of experienced-based heuristic for heat exchanger network
synthesis is quick and easy to apply.
Finally, the number of heat exchanger can be reduce since the heat and power
integration seeks to utilize the energy in high-temperature streams that need to be
cooled and to heat up the cold streams.
68
The first step in TI method is to adjust the source and target temperature using
Tmin. The temperature of the hot streams reduced to by Tmin while the
temperature of cold stream remains unchanged. The adjustment will bring both
streams to common frame of reference. Therefore when energy balance involve hot
and cold stream conducted, the calculation for heat transfer perform with at least a
driving force of Tmin.
Then, the adjusted temperature were rearranged in rank-order, starting with the
To the highest temperature. These orders are used to create a cascade of temperature
intervals within the energy balance that are carried out. Each interval will shows
enthalpy difference between the energy to be remove from the hot stream and the
energy to be consume by the cold stream in that interval.
Initially no energy is assumed to enter the first interval from a hot utility as the
heat duty. Hence the enthalpy is available for the next interval as residual. This will
continue to the next interval until the final residue is obtained which become the cold
duties.
Firstly, identification of the hot and cold streams in the plant before the heat
integration is carried out. All the streams in the plant must be calculated to obtain the
maximum energy recovery for the plant. The value of heat flow rate, FCp obtained
from energy balance summary where it is equal to H/T. There are several benefits
of HEN have been identified are;
Tmin varies the relative heat recovery status. A simple criterion to develop a pinch
technology design is as below;
a) Divide the problem at the pinch into separate problems that is the hot utility and
cold utility.
b) Design for separate problems is started at the pinch and moving away. The streams
are conveniently matched to the heat transfer streams.
temperature difference at the heat exchangers) of the matcher, CPH (hot stream)
should be smaller than or equals to CPC (cold stream) above the pinch while CPH
should be more than or equals to CPC below the pinch. However, the CP inequalities
only apply when both ends are match to the pinch point. Minimize the number of the
units.
d) Stream splitting is necessary to provide a flexible matching design.
Pinch analysis begins with the process of screening plant flow sheet for a set
of hot and cold streams having potential for heat interchange. These stream data can
be obtained directly from the simulation results. The extracted stream (which
excluding reboiler that involved the use of utilities) are tabulated in the following
table. The value of heat flow rate, CP is obtained from energy balance summary.
Table 4.1: Summary of Hot and Cold Streams (Tabulated from Simulation Results)
Heat
Exchanger
HX1
HX2
HX3
Stream
H1
H2
C1
Tsupply (C)
486.5
116.89
25
Ttarget (C)
-100
25
486.5
FCp (kW/K)
0.754873533
0.04260705
115.748725
71
From Problem Table and Heat Cascaded Diagram in Appendix B, the heat
utility, cold utility and no pinch temperature can be obtained.
The stream pairing target is to achieve the minimum heating value, Qcmin =
102.334 kW and minimum cooling value, Qhmin = 53073.7244 kW with minimum
number of heat exchanger.
For the above pinch design, the following rules must be fulfilled:
Only can pair stream where the cold stream FCp is greater than hot stream FCp, CpC
CpH
Start with the hot stream with biggest FCp
Maximize the heat exchange load and tick off the streams that enthalpy balance is
made.
Fill in the rest of the exchanger in the same manner, checking for temperature
feasibility for heat exchange
72
Above pinch can only have heater; cooler is prohibited in the above pinch region
The temperature difference of the hot and cold stream must be greater or equal to
Tmin = 10C
4.1.5
Table 4.2: Summary of the Heat Equipment Duties before and after MER
Stream
Before MER
After MER
Hot
0KW
53073.7224 KW
cool
52971.3904 kW
102.334 KW
73
QCmin = 102.334 kW
QHmin = 53073.7244 kW
4.2
Process Optimization
74
In this plant we will optimized reactor equipment by determining the optimal reactor
duty, used for the reaction. The main reasons to develop optimal reactor duty are:
1. Energy saving and
2. Reducing heating cost.
Product Fraction
Constraint;
Temperature, oC
Product Conversion
486.4893345
0.859069596
2100000
93.984965
0.863504024
1300000
83.26839222
0.874115191
1200000
68.89833112
0.775784018
1100000
21.75674261
0.4676652
1000000
-37.97626333
0.136044916
900000
-105.7586847
0.003707928
800000
75
500000.00
450000.00
0.874
0.864
400000.00
0.776
350000.00
300000.00
275564.18
254366.94
250000.00
233169.690.468
211972.45
200000.00
190775.20
169577.96
150000.00
100000.00
0.136
50000.00
0.0040.00
93.98
83.27
68.9
21.76
-37.98 -105.76
Temperature oC
445142.14
0.859
486.5
Product Conversion
TEMPERATURE
PRODUCT CONVERSION
83.27
0.874
250,000
From figure 4.1, the optimum condition obtain at 7oC with product fraction 0.393 with
reactor duty 995000 kJ/h. Optimizing of CRV 100 saved of the reactor duty.
2100000995000
21000000
x 100= 52%
76
Product Conversion
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
4.3
Waste treatment refers to the activities required to ensure that waste has the
least practicable impact on the environment. In many countries various form of waste
treatment are required by law. In this plant, we react dimethyl ether with hydrogen
and will produce carbon monoxide. Since this gas is toxic, it has to be treated before
release to the atmosphere. Thus, we need to find the standard for industries emitting
gaseous and air emission in Malaysia to propose the suitable treatment. Other than
treating, carbon monoxide also can be reuse for other industries such as hot iron
oxides and metallic ores industry.
Emission standards are requirements that set specific limits to the amount of
pollutant that can be released into the environment and maximum amount of a
specific pollutant allowed to be discharged into the atmosphere from a single fixed
or mobile source. According to Environmental requirement: A Guide for Investors
set by Department of Environment:
1. For industries emitting gaseous and air emission, they are required to
comply with the following air emission on standards for the control of air
pollution and gaseous emissions :
a. Stack gas emission standards from the Environmental Quality
(Clean Air) Regulations 1978 (Appendix J1)
b. Recommended Malaysian Air Quality Guidelines (Ambient
Standards) (Appendix J2)
2. All industrial projects subject to EIA shall be designed and operated using
Best Available Techniques (BAT) in achieving a high and acceptable level
of protection for the environment.
77
78
79
The emissions of carbon monoxide from our plant have been calculated, and
we find that our emissions are lower than the DOE standard, 9ppm/hr. Therefore,
the carbon monoxide emits from our plant no need to be treated.
4.4
Water treatment.
Water treatment is any process that makes water more acceptable for a specific
end-use. Water treatment will removes contaminant or reduces their concentration so
that the water becomes fit to the end user. Two of the main processes of industrial
water treatment are boiler water treatment and cooling water treatment. Water that use
for boiler and cooling tower need to be treated to reduce the scaling and corrosion.
Scaling in the boiler will reduce the heat production efficiency.
80
CHAPTER 5
5.1
Introduction
In this LPG production plant, it involves many major types of equipment in the set-up
of the plant. Generally, the units comprises of reactor, distillation column, flash column,
mixer, pump, heat exchanger and compressor. All the calculated data are tabulated in
Appendix C.
In this following section also shall discuss the general design procedure. In addition, the
assembly drawings showing mechanical engineering design of each process vessels and its
corresponding equipment specification sheet are also presented in the Appendix C, the detailed
calculation for mechanical engineering design of equipment is provided in Appendix C.
In this plant design, equipment sizing and costing will be referred to Product and
Process design Principles.
81
Equipment
Quantity
Heat Exchanger
Reactor
Flash Column
Distillation Column
Mixer
Pump
V-100
Operating Condition
Temperature (C)
-100
Pressure (atm)
1
Specification
Design type
Vertical vessel
Material of construction
Stainless steel
Vessel
Diameter (m)
0.3003
82
Height (m)
1.2012
Volume (m3)
0.5234
5.1.2 Pump
Pump selection is made on the flow rate and head required, together with other
process considerations, such as corrosion or the presence of solids in the fluid. Pump
generally can be divided into two different types, which are dynamics pumps and positive
displacement pump. Positive displacement itself can be separate to two other types known as
reciprocating pump diaphragm pump and centrifugal pump. The centrifugal pumps are the
major types that used in the chemical plant nowadays. Centrifugal pumps are used so
extensively and for such a wide variety of services that need for standardization of
dimensions and operating characteristic has long been evident.
A general guide to the selection, installation and operation of pumps for the processes
industries is given by Davidson and von Bertele (1999) and Jandiel (2000). The selection of
the pump cannot be separated from the design of the complete piping system. The total head
required will be the sum of the dynamic head due to friction losses in the piping, fittings,
valves and process equipment, and any static head due to differences in elevation. The
pressure drop required across a control valve will be a function of the valve design. Sufficient
pressure drop must be allowed for when sizing the pump to ensure that the control valve
operates satisfactorily over the full range of flow required. If possible, the control valve and
pump should be sized together, as a unit, to ensure that the optimum size is selected for both
PUMP P-100
PUMP P-101
OPERATING CONDITION
Temperature (C)
-98
26
83
6.9
30.9
14.8
SPECIFICATIONS
Driver type
Motor
Motor
75
75
Capacity [m3/h]
1.0368
1.1338
13.835
11.779
Carbon steel
Carbon steel
1.5090
0.3280
Pump Efficiency, %
Material of Construction
Shaft Power
The principal types of heat exchanger used in chemical process and allied industries are:
a) Double pipe heat exchanger: the simplest type, used for cooling and heating.
b) Shell and tube exchangers: used for all applications.
84
c) Plate and frame exchangers (plate heat exchangers): used for heating and cooling.
d) Air cooler: cooling and condensers.
e) Direct contact: cooling and quenching.
Since shell and tube exchanger is the most commonly used of heat transfer equipment used in
chemical and allied industries, it was chosen as the exchanger type in the design, the
advantages of this type are:
The designing procedures are based on the Kerns and Bells method (Sinnott, 1996). The
design produce is as below:
a) Define the duty: heat transfer rate, fluids flow rate and temperature.
b) Collect the fluid physical required: density, viscosity and thermal conductivity.
c) Decide the type of exchanger to be used.
d) Select the trial value for the exchanger to be used.
e) Calculate the mean temperature different, Tlm.
f) Calculate the area required.
g) Decide the exchanger layout.
h) Calculate the individual coefficients.
i) Calculate the overall coefficient and compare with the trial value.
If the calculated value differs from the estimate value, substitute the calculated value and
return to step (6)
Below is the summary table for sizing of heat exchanger:
85
25
486.5
500
353.23
Triangle
9.87 m2
Heat duty
349.82 kW
464.87
-100
-101.1
292.4
Triangle
15.26 m2
345.9 kW
86
116.89
25
5
20.3
Triangle
3.19 m2
Heat duty
1 kW
241.65 W/m2.oC
5.1.4 Reactor
Reactors are the main component of a chemical plant where the reactions take place to
convert the raw material to desired products. There are various parameters need to be take
into account when designing the reactors, namely type of reaction, concentration,
temperature, pressure, phase and catalyst used. There are also few types of reactors such as
the batch reactor, continuous stirred tank reactor and plug flow reactor. For the production of
LPG from DME, PFR was used to ensure high conversion of reactants.
In its most basis form a plug flow reactor consists of a cylindrical tube filled with
piping system. Reactants flow through the pipe and reacted with other reactants and are
converted into products. They may be regarded as the workhorse of the chemical industry
with respect to the number of reactors employed and the economic value of the materials
produced.
87
The catalyst constituting in the fixed bed will generally be employed in one of the
following configurations multiple horizontal pipe. Other constraints are including pressure
drop or adequate fluid distribution. In additional to the shell and tube configuration some of
the possibilities for heat transfer to or from plug flow reactors include the use of internal heat
exchanger, annular cooling spaces or cooling thimbles and circulation of a portion of the
reacting gases through an external heat exchanger.
Reactor CRV-100
Identification
Function
Temperature ()
475
Pressure (bar)
2.1
Flowrates
706.21 kg/hr
Amount of catalyst, W
1.36 kg/pipe
SPECIFICATIONS
Design type
Horizontal cylinder
Material of construction
No. Of unit
10
Residence time
1.94 hr
88
3.52
Length, m
14.08
Volume, m3
137.14
No. of pipes
7618
5.1.5.1
Plate Spacing
Plate spacing is the most important part for determining the overall height of the
column. Plates spacing ranges from 0.15 m to 1 m are normally used. The spacing chosen
depends on the column diameter and operating conditions. For columns above 1 m diameter,
plate spacing 0.3 to 0.6 m will normally be used and 0.45 m can be taken as initial. This will
be revised as necessary.
5.1.5.2
Column Diameter
89
The principle factor in determining the column diameter is the vapour flow rate. The
column diameter can be calculated by calculating the top and the bottom net area at its
maximum volumetric flow rate. The velocity is normally between 70 to 90% of what which
could cause flooding
5.1.5.3
Height of Column
The height of column in the distillation column is calculated by knowing the number
of actual stages. Minimum number of stages is calculated from Fenske Equation. The height
of the column can be calculated by multiplying the number of the actual stages with tray
spacing value.
Table 7,8 and 9
D-100 (de-ethanizer)
Function
Temperature,
-98
Pressure, bar
31
No.of tray
15
Thickness,inch
2.41
Weight
83906.71 lb
SPECIFICATION
Design type
Material of construction
Stainless steel
VESSEL
Diameter, inch
113.38
Height, m
14.4
90
D-101 (de-butanize)
Function
Temperature,
104.39
Pressure, bar
No.of tray
15
Thickness,inch
0.66
Weight
91190.94 lb
SPECIFICATION
Design type
Material of construction
Stainless steel
VESSEL
Diameter, inch
118.11
Height, m
15.0
91
D-102 (de-propanizer)
Function
Temperature,
37.85
Pressure, bar
15
No.of tray
15
Thickness,inch
1.03
Weight
91190.94 lb
SPECIFICATION
Design type
Material of construction
Stainless steel
VESSEL
Diameter, inch
118.11
Height, m
15
92
CHAPTER 6
PLANT COSTING
6.1
Introduction
After designing and sizing equipment in Chapter 5, the equipment and plant costing is
6.2
Equipment Costing
Costing for a plant is very important factor that should be done in good manner
because it's determined the whole plant profitability beside ensure that the plant run perfectly
without any losses and problems during the operation. In LPG production plant, it involves a
total of 11 units in the set-up of the plant. Generally, the units comprises of reactor,
distillation column, pump, heat exchanger and tank.
93
NAME
COST (RM)
Reactor
CRV-100
RM 2,851,990.64
Distillation column
D-100
RM 6,137,043.41
D-101
RM 7,469,667.30
D-102
RM 7,354,678.41
P-100
RM 675,307.84
P-101
RM 283,407.20
E-100
RM 222,956.78
E-101
RM 52,892.27
E-102
RM 276,211.85
V-100
RM 42,169.99
Pump
Heat Exchanger
Flash Column
LPG tank
RM 3,349,500.68
RM 28,715,826.37
94
6.3
industry and plant. This is for the purpose to determine the GRC which is a contribution of
bare module cost, contingency and fees as well as auxiliary facilities. According to Ulrich
(1984), the contingency and fees is 18% of bare module cost whereas the auxiliary facilities
hold 30% of the bare module cost.
CC = 0.15CTBM
RM 4,307,373.96
Fees
CF= 0.15CTBM
RM 4,307,373.96
Auxiliary Building
CAB = 0.04CTBM
RM 1,148,633
Site Development
CSD = 0.05CTBM
RM 1,435,791.32
Offsite Facilities
COS = 0.21CTBM
RM 6,030,323.54
0.30 CTBM
RM 37,330,574.28
RM 861,474.79
RM 38,192,049.07
95
6.4
Fixed Capital Investment (FCI) defined as financially immobile capital cost. This can
be simply analogised as the money, once spent, cannot be quickly converted back into cash or
some other asset. This includes direct costs, indirect cost and the GRC. Meanwhile for Total
Capital can be represented by the following question.
Working capital is refer to what must be invested to get the plant into productive
operation which is money invested before there is a product to sell. Generally, most of the
chemical plant used an initial working capital is 112% of the FCI and start-up cost is 8% out
of FCI (Ulrich, 1984).
96
Event
Onsite
Purchased Equipment Installation
30% GRC
RM 11,457,614.72
15% GRC
RM 5,728,807.36
Piping (installed)
30% GRC
RM 11,457,614.72
8% GRC
RM 3,055,363.93
Building
10 % GRC
RM 3,819,204.91
Yard Improvements
1% GRC
RM 381,920.49
Service Facilities
5% GRC
RM 1,909,602.45
Land
2% GRC
RM 763,840.98
Total
(T1)
5% GRC
RM 1,909,602.45
Construction Expenses
8% GRC
RM 3,055,363.93
Contractor's Fee
1.5% GRC
RM 572,880.74
Contingency
10% GRC
RM 3,819,204.91
Total
(T2)
RM 9,357,052.03
Total (T)
T = T1 + T2
RM 47,931,021.59
FCI = GRC + T
RM 86,123,070.66
Working Capital
12% FCI
RM 10,334,768.48
Start up
8% FCI
RM 6,889,845.65
(installed)
Offsite
RM 38,573,969.56
RM 103,347,684.80
97
6.5
For estimation labour cost, it will consider for 330 working days per year with an assumption:
Categories
Number
of unit
Operators per
unit per shift
Operators per
shift
Reactor
PFR reactors
0.50
0.50
Distillation
column
Produce
hydrocarbon from
DME
Separate
ethane
Separate
butane
Separate
propane
0.30
0.90
Pump
Increase pressure
0.0
0.00
Heat
exchanger
0.10
0.30
Storage tank
Stored LPG
0.00
0.00
Waste
Wastewater
treatment
2.00
2.00
Total
3.70
98
= 3.70 x 3
= 11.1
= 11 people
99
6.6
Unit ID
Cooler
E-102
312.00
Heat Exchanger
E-100
108,207.84
E-100
107,920.80
P-100
351.22
P-101
76.34
Pump
Material
Water
Total Utilities
100
6.7
DME (feed)
Hydrogen (feed)
RM 0.5974 /kg
RM 6.48/ kg
Hydrogen (feed)
RM 5,997,987.71
RM1.872 /kg
Product Amount:
LPG
1,219,830,025.491kg/year
RM 2,283,521,807.72/year
RM 2,283,521,807.72/year
101
6.8
Manufacturing Cost
Table 6.8: Manufacturing cost summary
RM 86,123,070.66
Working Capital
RM 10,334,768.48
RM 6,889,845.65
Start Up Cost
RM 103,347,684.80
Cost per
Manufacturing Expenses
Cost (RM/year)
production
(RM/kg)
7.07
5,998.00
48.83
226,816.67
0.04
1,722,461.41
0.07
8,612.31
0.00
264,000.00
0.01
26,400.00
0.00
26,400.00
8,612.31
0.00
0.00
861,230.71
0.03
861,230.71
132,000.00
0.03
0.00
10,616,494.83
56.08
Raw Material
Catalyst ( 0.1% raw material)
Utilities
Hot and cold utilities
Miscellaneous
Maintenance and repair (2% FCI)
Operating supplies (0.5% of maintenance &
repair)
Operating labor
Direct supervision & clerical labor (10% of
operating labor)
102
Cost (RM/yr.)
Cost per
Production
(RM/kg)
33,000.00
0.00
8% of FCI
6,889,845.65
0.27
3% of FCI
2,583,692.12
General Expenses
Administration
Cost
Distribution &
Selling Experiences
Research &
Development
25% of plant
overhead
9,506,537.77
0.10
0.37
= +
20,123,032.60
56.45
Depreciation, ABD
8,612,307.06
0.33
28,735,339.66
56.78
103
CHAPTER 7
7.1
Introduction
Chemical plants are physically large and complex. Process control is essential to
control the dynamic state of process. Terminologically, control is to measure, decide and
adjust the variable of a process to meet the requirements and certain objectives. The control
system and Piping & Instrumentation Diagram are both important because of the arrangement
of the processing units are integrated with each other in systematic and rational manner.
During in plant operation, these must satisfy several requirements imposed by the designer,
process requirements, economical and socially condition for any changes occurred that might
deviate it from the set point or become unsteady.
Typically, there were seven major control objectives listed according to Marlin
(2000). They are:
i.
Safety
ii.
Environmental Protection
Process control is required to satisfy the various federal and state laws
that specify the temperatures, concentrations and flow rates of the
effluent from a plant are within certain limits.
104
iii.
Equipment Protection
iv.
v.
Product Quality
vi.
Profit
To minimize the usage of heating and cooling utilities and then cut
down the utility cost
vii.
105
7.2
The typical process control concept is to satisfy the operational objectives. This
accomplished through a rational arrangement of equipment (measuring devices, valves,
controllers, computers) and human interventions, which together constitute the control system
and procedures. The three general classes of needs that a control system is called on to
satisfy:
In developing a particular control scheme, control objectives are first defined. Then,
critical controlled variables are identified, whereby measured variables, manipulated
variables must be decided to conceptualize the control strategies. The following procedure is
used to identify and locate the control instruments in the process:
1. Determine and draw the relevant control loops such as temperature control, pressure
control, composition control and flow control to confirm the steady state plant
operation.
2. Identify the key process variables that to be controlled to achieve the specified
product quality. Include controls loops using direct measurement of the controlled
variable, where possible.
3. Identify and include those additional control loops required for safe operation, not
covered in steps 1 and 2.
4. Decide and show those auxiliary instruments needed for the monitoring of the plant
operation by the operators and for trouble-shooting.
5. Decide also on the alarms needed. There are two types of the control system namely
feedback control and feed forward control.
106
6. In feedback control system, that applied where there is a measuring device detecting
the output of the process and then a controlling device will compare the measured
reading and the process set point, sending signal to the final control element that will
manipulate the controlled variables.
7. Unlike the feedback control system, forward control configurations measures the
disturbance (load) directly and take control action to eliminate its impact on the
process output. Therefore, feed forward controllers have the theoretical potential for
perfect control.
7.3
coolant. The life span of the equipment can be preserved as long as the
temperature deviation is small
7.4
Chemical Process:
It indicates the material equipment together with the physical or chemical
operations that occur there.
ii.
Sensor:
These measuring instruments are used to measure the disturbances, the
controlled output variables, or secondary output variables. It represents the
behavior of the process. For instance, thermocouple, venture meter and gas
chromatographs.
iii.
Transducer:
It used to convert measurement to physical quantities (such as electrical
voltage or pneumatic signal) which can be transmitted easily
iv.
Transmission line:
108
The line is used to carry the measurement signal from the measuring device to
the controller. Sometimes it is equipped with amplifier due to weak signal
coming from a far measuring device.
v.
Controller:
This is the hardware element that has intelligence. It receives the
information and decides what action should be taken.
vi.
vii.
Recording Elements:
They are used to provide a visual demonstration of how a chemical process
behaves.
7.5
109
7.6
Measured
Manipulated
Disturbance
Configuration
Variable
Variable
Variable
Temperature
Temperature
Flowrate of
Ambient
Feedback
of reactor
of reactor
cooling
temperature
control
Set Point
of Controller
T=475
utilities
stream
Pressure of
Pressure of
Inlet flow
Feedback
reactor
reactor
rate
control
P=2.1 bar
Alarm is set to ring when the set point is exceeded by +5% (high alarm) or -5% (low
alarm) for all controllers.
110
Indication :
Major Pipeline :
Signal Pipeline :
111
Heat Exchangers
Objective: To control the temperature of stream at desired value so that the plant operates
safely and can achieve maximum energy recovery
Table 7.2 : Control System for Heat Exchanger (HX-100 and HX-101)
Control
Variable
Measured
Variable
Manipulated Disturbance
Variable
HX-100
Temp of inlet Temp of inlet Flow rate of
Inconsistent
stream (Sstream (Sprocess
temperature
DME)
DME)
stream (S1of process
EXP)
stream (S1EXP) and
ambient
temperature
HX-101
Temp of inlet Temp of inlet Flow rate of
Inconsistent
stream (Sstream (Sprocess
temperature
DME)
DME)
stream (Sof process
B2)
stream (S-B2) and
ambient
temperature
486.5C
Feedback
Control
486.5C
Alarm is set to ring when the set point is exceeded by +10% (high alarm) or 10% (low
alarm) for all controllers.
112
Figure 7.1: Control System for Heat Exchanger (HX-100 and HX-101)
HX-100
HX-101
Title :
Indication :
Electrical signal
Pneumatic signal
Control valve
113
Cooler
Objective: To control the temperature of stream at desired value so that the plant operates
safely and can achieve maximum energy recovery
Measured
Variable
Manipulated
Variable
Disturbance
E-101
Temp of
outlet stream
(S-2-CL)
Ambient
temperature
Feedback
Control
-100C
Feedback
Control
25C
E-102
Temp of
outlet stream
(S-B2-CLR)
Temp of
outlet stream
(S-B2-CLR)
Flow rate of
cooling
utilities
Ambient
temperature
114
E-102
Title :
Indication :
Electrical signal
Pneumatic signal
Control valve
115
Heater
Objective: To control the temperature of stream at desired value so that the plant operates
safely and can achieve maximum energy recovery
Measured
Variable
Manipulated
Variable
Disturbance
E-100
Temp of inlet Temp of inlet Flow rate of
stream (Sstream (Sheating
DME)
DME)
utilities
Ambient
temperature
Feedback
Control
486.5 C
Title :
Indication :
Electrical signal
Pneumatic signal
Control valve
116
Measured
Variables
Variables
Feed to column
Disturbances
Flow rate of
Flowrate of
outlet of
outlet of
depressurizing
depressurizing
valve
valve
Level of liquid
Level of liquid
in column
in column
Manipulated
Variables
Set Point
Feed flowrate
13.8099 kmol/hr
Flowrate of
Avoid flooding
reflux ratio
bottom stream
in the reboiler
and condenser
Temperature of
Temperature of
Feed
Flowrate from
4.78 C (top)
column
each tray
temperature,
depressurizing
104.39 C
feed flowrate
valve
(bottom)
[others tray
temperature
between this
range]
Pressure of
Pressure of top
Feed pressure,
Flowrate of
column
tray
feed flowrate
distillate
454.7 psia
117
Alarm is set to ring when the set point is exceeded by +10% (high alarm) 0r -10% (low
alarm) for all controllers
Figure 7.4: Control System for Distillation Column, D-101
PC
101
TC
101
PT
101
TT
101
FT
101
FC
101
LT
101
LC
101
Indication :
Major Pipeline :
Signal Pipeline :
118
We will describe generally about the control objective of the distillation column.
Control objectives of our distillation column are as below:
1. Maintain a constant feed flow rate to the column.
2. Control the temperature of the column to maintain it at desirable level.
3. Control the pressure of the column at desirable level.
4. Control the liquid level in distillation column from flooding or from being too low.
5. Control the composition of the distillate stream at desired level.
6.
Table 7.5: Control System of Distillation Column, D-102
Control
Measured
Variables
Variables
Feed to column
Manipulated
Disturbances
Flow rate of
Flowrate of
outlet of
outlet of
depressurizing
depressurizing
valve
valve
Level of liquid
Level of liquid
in column
in column
Variables
Set Point
Feed flowrate
13.1115 kmol/hr
Flowrate of
Avoid flooding
reflux ratio
bottom stream
in the reboiler
and condenser
Temperature of
Temperature of
Feed
Flowrate from
36.36 C (top)
column
each tray
temperature,
depressurizing
111.12 C
feed flowrate
valve
(bottom)
[others tray
temperature
between this
range]
Pressure of
Pressure of top
Feed pressure,
Flowrate of
column
tray
feed flowrate
distillate
101.53 psia
Alarm is set to ring when the set point is exceeded by +10% (high alarm) 0r -10% (low
alarm) for all controllers
119
PC
101
TC
101
PT
101
TT
101
FT
101
FC
101
LT
101
LC
101
Indication :
Major Pipeline :
Signal Pipeline :
120
Measured
Variables
Variables
Feed to column
Manipulated
Disturbances
Flow rate of
Flowrate of
outlet of
outlet of
depressurizing
depressurizing
valve
valve
Level of liquid
Level of liquid
in column
in column
Variables
Set Point
Feed flowrate
11.7827 kmol/hr
Flowrate of
Avoid flooding
reflux ratio
bottom stream
in the reboiler
and condenser
Temperature of
Temperature of
Feed
Flowrate from
28.65 C (top)
column
each tray
temperature,
depressurizing
77.89 C
feed flowrate
valve
(bottom)
[others tray
temperature
between this
range]
Pressure of
Pressure of top
Feed pressure,
Flowrate of
column
tray
feed flowrate
distillate
159 psia
Alarm is set to ring when the set point is exceeded by +10% (high alarm) 0r -10% (low
alarm) for all controllers
121
PC
101
TC
101
PT
101
TT
101
FT
101
FC
101
LT
101
LC
101
Indication :
Major Pipeline :
Signal Pipeline :
122
The control system introduce for the flash column is designed to operate column
optimally and safely.
Objective: To remove carbon monoxide, CO in the stream that exist in gas phase. Two
different phases, one as liquid phase and one as vapour phase will be separated in the column
where the gas will go to the top while liquid at the bottom.
Control System:
1. To maintain the flash column pressure at 1 atm and to prevent the column from
overpressure.
2. To maintain the liquid level in the flash so that it will not overflow or dry out. This is to
ensure the
system interface always exist in order to make the flash column operate.
Measured
Manipulated
Disturbance
Variable
Variable
Variable
Pressure in
Pressure in
Outlet gas
Inconsistent
Feedback
flash column
flash column
pressure at
pressure at
control
upper
the inlet
of Controller
P = 1 atm
stream
Liquid level
Liquid level
Outlet liquid
Inconsistent
Feedback
Liquid do
in flash unit
in flash unit
flow rate at
flow of inlet
control
not exceed
bottom
stream
more than
1.0181 m
Alarm is set to ring when the set point is exceeded by +10% (high alarm) or 10%
(low alarm) for all controllers.
123
Title :
Indication :
Electrical signal
Pneumatic signal
Relief valve
124
Title :
Indication :
Electrical signal
Pneumatic signal
125
Measured
Manipulated
Variable
Variable
Variable
Outlet
Outlet
Pump
flowrate
flowrate
efficiency
Disturbance
Configur. of
Set Point
Controller
Feed
Feedback
The outlet
pressure
pressure is at
Feed
31 bar
flowrate
Measured
Manipulated
Variable
Variable
Variable
Outlet
Outlet
Pump
flowrate
flowrate
efficiency
Disturbance
Configur. of
Set Point
Controller
Feed
Feedback
The outlet
pressure
pressure is at
Feed
15 bar
flowrate
126
LT
LC
Manipulated
Variable
Varible
Disturbance
Type Of
Set Point
Controller
Feedback
Not sure
tank
127
CHAPTER 8
8.1
Introduction
Process safety study is an important factor in designing a chemical plant to avoid
major accidents in the designed plant. Furthermore, it ensures the safety of the workers,
public and environment. Safety study is most effective to carry out early in a project for
reducing the hazardous characteristics of a planned process. The main hazards in chemical
plant are toxic and corrosive chemicals, explosions, fires and accidents common to all
industrial activities. In this topic, various process safety techniques, general plant safety
study, plant start-up and shutdown and the concept of hazard and risk will be discussed.
Finally, hazard and operability study (HAZOP) on various unit operations will be done.
8.2
reactors, flash, heat exchangers, pumps, compressors, distillation columns and storage tank.
When the studies are applied to this equipment, the potential hazards, which may arise from
the deviations actions required to that should be taken, can be identified.
128
Process
Deviation
Possible cause
Possible consequences
Action Required
parameters
Valve
Flow
NO
(feed in)
2. Valve is blocked
HIGH
1. Control valve is
completely open
2. Controller doesnt
function
much
129
LOW
Reactor
Pressure
HIGH
LOW
1. Have leakage
2. Install additional
well
decrease
pressure controllers
3. Stop the leakage if any
existing
Temperature
HIGH
130
2. Install temperature
be controlled
LOW
controller
Reactor flow
Flow
NO
1. Line blockage
(outlet
stream)
1. Product loss
2. Downtime to overall
process
valves
LESS
1. Line fracture
2. Valve failure
131
Guide Word
Deviation
Less
Less
flow
of
Possible Causes
Consequences
Action Required
cooling medium
Pipe
Temperature
blockage
of
Control
fluid remains
valve
constant
failure
process
Install High
Temperatur
e Alarm
Install filter
Effect
at
the
further
coolant pipe
process
More
More
cooling
medium flow
Failure
of
Temperature
cooling
of
medium
fluid
valve
decrease
Failure
of
process
Install Low
Temperatur
e Alarm
Do
Effect
maintainanc
the coolant
further
pump
process
accordingly
to the valve
and
the
pump
None
No
cooling
medium flow
Failure
of
Process fluid
Install
inlet
temperature
Temperatur
cooling
is
e Indicator
not
132
medium
valve
to
open
lowered
before and
accordingly
after
Effect
process
fluid line
Pipe broken
further
Pipe
process
the
Install
backup
plugging
coolant line
Reverse
Reverse process
Failure
fluid flow
of
process
fluid
Product
offset
inlet
Install
check valve
Effect
Ensure
valve
further
pump
Coolant
process
good
pump
not
functioning
is
Difficult
to
condition
control
the
regularly
temperature
flowing out
Contamination
Process
contaminated
and
maintainance
medium goes in
and
operator
alert
Guide Word
Deviation
Possible Causes
Consequences
Action Required
More
Higher
temperature
Temperature
of the process
fluid is too
high
Fire occured
near the heat
Pressure will
increase
Temperatur
Explosion
e Alarm
could occur
Install High
Failure
other
of
Repair
damage
part of the
133
exchanger
Failure
equipment
heat
exchanger
of
heat
exchanger
Less
Lower
temperature
Failure
of
Temperature
control
increases
system
with
No
coolant
flow
stream
Install Low
Temperatur
that
Failure
e Alarm
condition
temp
change at the
of
Tube of the
equipment
other
should
equipment
cleaned
be
Condensation
often
to
occurs at the
remove the
tube of the
deposit
equipment
134
Deviation
No flow
Possible
Action
Consequences
causes
required
Pipe blockage
Possible
Valves fail
dangerous
concentration
maintenance
No operation
procedure
blocking
Check
and
schedule
Pump failure
Make bypass
Emergency plant
shut down
LESS
Less Flow
Pipe blockage
Changes
Valves fail
maintenance
blocking
procedure
alarm
in
product quality
Pump failure
Check
Make bypass
Emergency
plant
shut down
MORE
More flow
Control
valve
fully opened
is
Flooding in the
column
Increase
pumping
capacity
Control
valves
failure
Changes
in
Check
product quality
maintenance
Temperature
procedure
decrease
schedule
Rise in bottom
and
Install
control
valves
liquid level
Install
flow
indicator
HIGH
High
pressure
Pressure
Make bypass
Install
of separation
indicator
controller fail
Low efficiency
Rupture
high
pressure alarm
of
column or other
Install
pressure
relief valve
related
equipment
High
Temperature
Instrumentation
Product loss
Separation
failure
Exchanger
Cooling
Low
operator
on procedure
Column
Attention to heat
column
control
Reboiler
reboiler
control
Heating
medium
Phase effect
Pressure
and
changes
Low efficiency
of separation
Instruct
condenser failure.
pressure
Low
controller
in
in
Changes
Film boiling in
water
failure
indicator
flooding
Install temperature
cannot be done
product quality
tube
failure
Instrumentation
Loss of products
Pressure change
Install
pressure
indicator
Install temperature
136
failure
Product loss
Changes
Loss
temperature
of
heating
in
Instruct
operator
on procedure
product quality
Ineffective
Upgrade isolation
separating
Attention to heat
and temperature
process
input
Phase effect
control
(steam leakage)
indicator
Ineffective isolation
and
Deviation
Possible Causes
Consequences
More
Liquid level
Control
valve failure
Action Required
Flooding in
Install level
column
indicator
Install high
level alarm
Less
Liquid level
Blockage in
No product
inlet stream
Install level
indicator
Install
alarm
137
out
Deviation
Possible Causes
Consequences
Low
Pressure
Input
stream
leakage
Loss
Action Required
of
Install
products
pressure
Backward
indicator
flow occur
Install
backward
check valve
High
Pressure
High
pressure in
input
stream
Expander
malfuction
Column
rupture
Loss
Install high
pressure
stream
of
alarm
product
Install
overpressur
e
relieve
valve
138
HAZOP study on pump is important in order to maintain desired pressure into the distillation
column. To achieve that, the pump must maintain either the pressure or flow to the desired
pressure and flow.
Table 8.7 : HAZOP Studies on Pump Flow
Guide Word
Deviation
Possible Causes
Reverse
Flow
Consequences
Action Required
Pump motor
Contain
failure/not
high amount
backward
enough
of vapour in
check valve
suction
stream
Install
Install
backflow
alarm
More of
Flow
Pump
Floods
in
Install
failure/over
distillation
overflow
power
column
alarm
with
automatic
shutdown
No or Not
flow
Less of
flow
no flow/low
Install
failure
pressure
level alarm
Stream
stream into
at
blockage
distillation
distillation
column
column
Pump
Pump
Low
low
the
Install flow
failure
pressure
pressure
Stream
stream
alarm
blockage
139
Deviatio
Possible cause
Consequences
More of
Flow
Failure of
control valve
Flooding inside
storage tank
More of
Pressure
Failure of
control valve
Tank will
rapture or burst
Action
Required
Install
backward
overflow alarm
with autoshutdown.
Install pressure
relief valve and
install high
pressure alarm
140
CHAPTER 9
PROFITABILITY ANALYSIS
9.1
Introduction
The economic analysis that involves the computation of the monetary investment that
needs to pour into the plant should come before, because its one of the most essential parts
of the entire process design. The calculation involves the economic potential (Chapter 1) for
the selected plant was just a rough estimation in which the calculation does not count in other
factors such as depreciation, plant lifetime and so on the analysis will based on costing
calculation from Chapter 6. Actually there are three parameters when discussing economic
attractiveness: rate of return, Discounted Cash Flow Rate of Return (DCFRR) and NPV.
Here, DCFRR is the main interest because it is designed to reflect the actual interest on
investment and it is useful in comparing alternate possibilities.
20,123,032.60
56.45
Depreciation, ABD
10% FCI
8,612,307.06
0.33
ATE =APC+ABD
28,735,339.66
56.78
APC
141
2,283,521,807.72
2,254,786,468.06
Income Tax
631,340,211.057
1,623,446,257.00
9.2
((ANNP + ABD)/TCI)*100
1579.19 %
The cash flow diagram cited the overall flow of the monetary. From the calculation
and diagram, the payback period (PBP) can be estimated. In this plant, it is assumed that the
plant will only start operate to produce ethylene glycol after 3 year of setup. This explains
why the cash flow is negative for the first three years as the funder invest in the plant. It is
reasonable to estimate that most of the chemical plants life is from 15 years to 20 years. Here
the operating period is 20 years with the initial 3 years of start-up operation. The TCI is
funded accordingly in 1st year, 2nd year and 3rd year by the percentage of 20%, 40% and
40%. Due to start-up problem, the total annual sales only yield 80% for the first production
year (4th year). But as time goes by, starting from next year (5th year) the annual sales is
optimum. Table 12.1 and Table 12.2 are constructed to analyze the cash flow behavior at i =
0% and various discounted value.
142
Table 9.2: Undiscounted Cash Flow Analysis (Values in parentheses indicate negative cash flows
143
Completion
of Year
Annual
Capital
Investment,
Ai
Sales Income, As
Depreciation,
ABD
Total
Expenses Less
Depreciation,
ATE -ABD
Cash Income,
ACI = AS +(ATE ABD)
Allowances,
AA
Net Profit,
ANP=ACI-ABD
Federal Income
Taxes,
AIT=28%ANP
Cumulative Cash
Flow
0.00
-20669536.96
-20669536.96
-20669536.96
-41339073.92
-41339073.92
-62008610.88
-31004305.44
-31004305.44
-93012916.32
1826817446
8612307.06
20123032.60
1846940478.6
0.00
1838328171.54
514731888.03
1323596283.51
1332208590.57
1239195674.25
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
2911742130.80
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
4584288587.34
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
6256835043.89
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
7929381500.44
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
9601927956.98
10
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
11274474413.53
11
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
12947020870.08
12
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
14619567326.63
13
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
16292113783.17
14
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
17964660239.72
15
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
19637206696.27
16
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
21309753152.82
17
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
22982299609.36
18
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
24654846065.91
19
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
26327392522.46
20
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
27999938979.00
21
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
29672485435.55
22
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
31345031892.10
144
-93012916.32
2283521807.72
8612307.06
20123032.60
2303644840.32
0.00
2295032533.26
642609109.31
1652423423.95
1672546456.55
33017578348.65
4.00E+08
2.00E+08
23
0.00E+00
0
Working Capital
(RM -93012916.32)
-2.00E+08
Time (Year)
145
Table 9.3: Discounted Factor Cash Flow Analysis for 5% & 10% & 15% (Values in parentheses indicate negative cash flows)
i= 0%
Completion
of Year
0.00
-20669536.96
-20669536.96
-41339073.92
Cumulative
Cash Flow,
ANCI
i= 5%
Discount
Factor, fd
i= 10%
Discounted Cash
Flow, fdANCI
Cumulative Cash
Flow, ANCI
0.00
0.00
0.95
-19636060.11
-19636060.11
-62008610.88
0.91
-37618557.27
-31004305.44
-72343379.36
0.86
1332208590.57
1301204285
1672546456.55
Discount
Factor, fd
i= 15%
Discounted Cash
Flow, fdANCI
Cumulative Cash
Flow, ANCI
0.00
0.00
0.91
-18809278.63
-18809278.63
-57254617.38
0.83
-34311431.35
-26663702.68
-83918320.06
0.75
0.82
1092411044.27
1008492724.21
3004755047
0.78
1304586236.11
1672546456.55
3345092913
0.75
1672546456.55
3345092913
1672546456.55
Discount
Factor, fd
Discounted Cash
Flow, fdANCI
Cumulative Cash
Flow, ANCI
0.00
0.00
0.87
-17982497.16
-17982497.16
-53120709.99
0.76
-31417696.18
-49400193.33
-23253229.08
-76373939.07
0.66
-20462841.59
-69863034.92
0.68
905901841.59
829527902.52
0.57
759358896.62
689495861.70
2313078960.32
0.62
1036978803.06
1866506705.58
0.50
836273228.27
1525769089.97
1254409842.41
3567488802.73
0.56
936626015.67
2803132721.25
0.43
719194976.32
2244964066.29
0.71
1187507984.15
4754996786.87
0.51
852998692.84
3656131414.08
0.38
635567653.49
2880531719.78
3345092913
0.68
1137331590.45
5892328377.33
0.47
786096834.58
4442228248.66
0.33
551940330.66
3432472050.44
1672546456.55
3345092913
0.64
1070429732.19
6962758109.52
0.42
702469511.75
5144697760.41
0.28
468313007.83
3900785058.27
10
1672546456.55
3345092913
0.61
1020253338.49
7983011448.01
0.39
652293118.05
5796990878.46
0.25
418136614.14
4318921672.41
11
1672546456.55
3345092913
0.58
970076944.80
8953088392.81
0.35
585391259.79
6382382138.26
0.21
351234755.87
4670156428.28
12
1672546456.55
3345092913
0.56
936626015.67
9889714408.47
0.32
535214866.10
6917597004.35
0.19
317783826.74
4987940255.03
13
1672546456.55
3345092913
0.53
886449621.97
10776164030.44
0.29
485038472.40
7402635476.75
0.16
267607433.05
5255547688.07
14
1672546456.55
3345092913
0.51
852998692.84
11629162723.28
0.26
434862078.70
7837497555.45
0.14
234156503.92
5489704191.99
15
1672546456.55
3345092913
0.48
802822299.14
12431985022.43
0.24
401411149.57
8238908705.02
0.12
200705574.79
5690409766.78
16
1672546456.55
3345092913
0.46
769371370.01
13201356392.44
0.22
367960220.44
8606868925.46
0.11
183980110.22
5874389877.00
17
1672546456.55
3345092913
0.44
735920440.88
13937276833.32
0.20
334509291.31
8941378216.77
0.09
150529181.09
6024919058.08
18
1672546456.55
3345092913
0.42
702469511.75
14639746345.07
0.18
301058362.18
9242436578.95
0.08
133803716.52
6158722774.61
19
1672546456.55
3345092913
0.40
669018582.62
15308764927.69
0.16
267607433.05
9510044012.00
0.07
117078251.96
6275801026.57
20
1672546456.55
3345092913
0.38
635567653.49
15944332581.18
0.15
250881968.48
9760925980.48
0.06
100352787.39
6376153813.96
146
21
1672546456.55
3345092913
0.36
602116724.36
16546449305.53
0.14
234156503.92
9995082484.40
0.05
83627322.83
6459781136.79
22
1672546456.55
3345092913
0.34
568665795.23
17115115100.76
0.12
200705574.79
10195788059.18
0.05
83627322.83
6543408459.61
23
1672546457
3345092913
0.33
551940330.7
17667055431
0.11
183980110.2
10379768169
0.04
66901858.26
6610310318
147
RM360,000,000
i= 0%
i= 5%
i= 10%
i= 15%
RM270,000,000
RM180,000,000
0.5
1.5
2.5
3.5
4.5
(RM90,000,000)
(RM180,000,000)
(RM270,000,000)
Time (Year
148
From Figure 12.1, the PBP shows 1 years and half months after 3 years of start-up
period. This means at i = 5%, the plant will start earning after the PBP. According to Ulrich
(1984), the PBP lays between the start-up of a plant to the recovery of working capital. The
discounted cash flow rate of return (DCFRR) is the point in which the rate results a Net
Present Value (NPV) to zero. From Figure 12.2, within the period of 5 operating years, the
NPV will be approaching zero value even having the highest i 15 %. The DCFRR point is
the maximum interest rate that counted after the taxes. If the rate of interest in market is 10%,
the payback period of this plant is roughly 1 years and half month after the start-up year. This
means that the plant is profitable to construct even though the payback period is longer than
undiscounted cash flow. This is because that the equipment will undergo regular maintenance
and services. This will help to make sure that our plant can sustain for more than 15 years of
operation and have a good net value profit.
9.3 Conclusion
After carried out the economic analysis to the ethylene glycol production plant, it has been
meet up a few conclusions:
a) The Total Capital Investment is RM 103,347,684.80
b) The Total Expenses is RM 10,616,494.83 per year
c) The total utilities cost is RM 226,816.67 per month
d) The total operating labor costs is RM 264,000.00 per year
e) From Undiscounted Cash flow diagram, Pay Back Period is estimated at 1 years
and half months after start up period at i = 5%.
f) The rate of returned obtained after the taxes is 1579.19 %.
149